Homebrew phase plugs

[loninappleton]

Originally posted by Cal Weldon
It was Alex that helped you, I'm the one with the question about the shape of your plug. Gotta pic?

You know what farm grain elevator looks like? That' the shape.
No bulbous end.
The dowel is cut. The egg is cut to match the diameter.

I then hand sand it down until looks right and fits behind my grille.

The shop made grille has magnet fasteners and I was able to add a couple round magnets 3/4 into get some additional depth. The magnets are sold at home stores.

The grill is a system recommended here in the forums-- or maybe Bill Fitzmaurice --years ago: a screen door track with fabric instead of aluminum mesh. Those actually came out quite good looking. The system comes with corner fasteners and you get as much spline and track as you need. Same tools as making a screen door. You cut the dimension to size.

[Alex from Oz]

Here's the link to the pattern.

[loninappleton]

Originally posted by Alex from Oz
Here's the link to the pattern.

Didn't see it.

[loninappleton]

Originally posted by loninappleton



Didn't see it.

Sorry that was rude. Do you know the post number?

[Alex from Oz]

Post #15 on the EnABL Processes thread (see 14 and 16 also).

Love to see some pics of your phase plug too!

Cheers,

Alex

[loninappleton]

Originally posted by Alex from Oz
Post #15 on the EnABL Processes thread (see 14 and 16 also).

Love to see some pics of your phase plug too!

Cheers,

Alex

My interest in technology never went as far as cameras of any kind
though I would consider a 5-10 megapixel jobbie for $50 or less.

Yes it has handicapped me a bit here in this forum.

For the phase plug it's just a piece of doweling about 2.5 inches long with the small end of a wooden craft egg on one end. The wooden craft eggs are $1.47 USD for 6. Craft eggs are in the hobby stores next to the wooden plaques for rosemalling and such.

By all means if you know of a rocket shaped piece of plastic that is hollow and the same diameter as the dustcap on 4 in speaks, that would solve everyone's problem in doing this: if there were a molded piece of plastic that could be cut to length and looked like a kid's rocket ship, cutting the dust cap would not be necessary and the process would be nearly totally reversible.

I've looked for every source of such a pre-made piece and nothing.
Closest thing was some chrome plastic "bullets" used in automobile customizing. I've checked for party favors and parts in the Edmund's catalog plus a bunch of other places. Bullet thingies is the right shape.

What keeps me from buying any is the distance from Dave and the fact that I'm a cheap @ss. (See if the forum police catch that.)

cheers.

[loninappleton]

Note to self:

What might work is one of those chubby Sharpie markers designed for making posters: bigger than the usual magic marker felt tip pens and might be the right diameter.

I'll see the next time I'm in the office supply place.

[Cal Weldon]

Yes the police caught it but since it could also mean a frugal donkey, we'll let it pass.

I think if I were to make my own phase plugs with limited tools, I would start with a dowel and screw a hex head bolt into the center. I would place that into a cordless drill and strap it to the bench on it's side. Then while it's spinning I would use a very coarse sand paper to begin the round off and use successively smaller grits once the basic bullet nose shape is formed. Remove it from the drill, remove the bolt, cut to size so you have cut off the mounting hole, drill two small pilot holes for very small flat head screws, countersink the holes, add the screws for the magnetic attachment to the pole piece and be done with it. Oh wait, I forgot the step of using a nice Watco Fruitwood stain or WHY for the finish.

[Cal Weldon]

I think those markers have an aluminum housing so you'd have to glue it to the pole piece. Same with anything plastic.

Some people have used modified sockets

[Alex from Oz]

I was given an award/trophy made out of a solid clear block of acrylic (perpex?).
It seems to be a very inert material. I have always wondered whether it would be any good for a phase plug.
Considered building some speaker enclosures from it - until I found out how much it costs $$$

Nice ideal with the drill Cal. I was thinking along the same way but wasn't sure how to secure it into the drill. Have you actually made phase plugs this way?

Lon,
I think for a phase plug to work as intended it needs to be fixed to the pole piece, making dust cap removal unavoidable.